owner’s manual · 2020. 12. 23. · owner’s manual “operation, maintenance & parts”...

Owner’s Manual

“Operation, Maintenance & Parts”

Portable Feeder

Model #: 4240-16

Unit Serial #: 194240429 Hikon W/O: 3285

Shipping Address – Hikon Industries Ltd., Lot One – Yellowhead Industrial Park, Saskatoon Sask. Mailing Address – Hikon Industries Ltd., Site 412 – Box 279 R.R. 4, Saskatoon, Sask. S7K 3J7

Office: (306) 244 – 4533 Fax: (306) 244 – 5223

Owner’s Manual “Operation, Maintenance & Parts”

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TABLE OF CONTENTS EQUIPMENT PICTURE ................................................................................ 3 EQUIPMENT PICTURE (AUTOCAD) ........................................................ 4 G.A. DRAWING TRANSPORT .................................................................... 5 OPERATION & MAINTENANCE ............................................................... 6 PRE-INSPECTION ........................................................................................ 7 EQUIPMENT SPECIFICATIONS ................................................................ 8 DELIVERY INSPECTION .......................................................................... 10 LIMITED WARRANTY .............................................................................. 11 SAFETY ....................................................................................................... 12

GENERAL PRECAUTIONS & WARNINGS ............................................................. 12 LOCKOUT ................................................................................................................... 12 DECALS ....................................................................................................................... 12 DO’S & DON’TS ......................................................................................................... 13

MAINTENANCE ......................................................................................... 14 GENERAL .................................................................................................................... 14 LUBRICATION ........................................................................................................... 15 PULLEY MAINTENANCE ......................................................................................... 15 BUSHING INSTALLATION & MAINTENANCE .................................................... 15 HYDRAULIC MAINTENANCE ................................................................................. 17 TAKE-UPS ................................................................................................................... 17 BELT TENSION & REPAIR ....................................................................................... 17 CONVEYOR BELT TROUBLE-SHOOTING ............................................................ 18

OPERATION INSTRUCTIONS .................................................................. 20 PRE-OPERATION CHECKLIST ................................................................................ 20 EQUIPMENT SETUP FROM TRANSPORT.............................................................. 21 EQUIPMENT SETUP TO TRANSPORT ................................................................... 21

PLANT SPECIFIC OPERATING INSTRUCTIONS .................................. 22 TRANSPORT TO OPERATING POSITION .............................................................. 22 OPERATING TO TRANSPORT POSITION .............................................................. 23 OPERATION AND ADJUSTMENT ........................................................................... 23

PARTS .......................................................................................................... 26 PARTS LISTING.......................................................................................................... 26 REPLACEMENT ROLLS ............................................................................................ 27 PARTS DRAWINGS.................................................................................................... 28

MANUFACTURERS BROCHURES .......................................................... 42 DODGE QUANTIS REDUCER .................................................................................. 42 DODGE REDUCER ..................................................................................................... 54 DODGE BACKSTOP ................................................................................................... 61 ROLLER BEARINGS .................................................................................................. 82 IMPACT BED .............................................................................................................. 88 TB WOODS BELT DRIVE TENSION ..................................................................... 106 TB WOODS BUSHING ............................................................................................. 112 WEG MOTOR ............................................................................................................ 113


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EQUIPMENT PICTURE


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EQUIPMENT PICTURE (AUTOCAD)


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` G.A. DRAWING TRANSPORT


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OPERATION & MAINTENANCE

It is important that the “Owners, Operators, and Anyone” working with this equipment read and understand this manual. This manual provides operation, lubrication and maintenance information. As Hikon Industries Ltd. progresses, improvements to our products may cause changes to your equipment, which may not be reflected in this publication. We reserve the right to make changes and improvements to our products at any time, without incurring any obligation to make changes to previously manufactured equipment. Hikon Industries Ltd. does not assume any liability for errors or omissions in this publication. Failure to read and understand this manual may cause serious injury or equipment malfunction. Hikon Industries Ltd. does not assume any liability for any injury, death, damage or cost caused by any act or omission on the part of the Owner, Operator or other personnel, agent, contractors, venders and others. PRINTED IN CANADA. All rights reserved. This manual may not be reproduced in any fashion without the consent of HIKON INDUSTRIES.

PARTS, SALES & SERVICE BUSINESS HOURS: 7:00am – 4:30pm MONDAY – FRIDAY CLOSED ON STAT HOLIDAYS BUSINESS: (306) 244 – 4533 AFTER HOURS: (306) 244 – 4533 FAX: (306) 244 – 5223


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PRE-INSPECTION

IMPORTANT! MUST READ BEFORE OPERATION

New equipment must receive a pre-operation inspection and adjustment. *INITIAL DELIVERY CAN LOOSEN HARDWARE AND CONNECTIONS* Areas directly affected by highway travel & initial start-up: trough sets, sheaves, sprockets and pulleys mounted to shafts with removable bushing-type hubs. Components are mounted securely at the factory but will go through a seating process during the primary startup. Electric motor drive direction must be checked prior to installing drive belts. For the first month of operation; all bushings and cap screws should be checked once a week, then during regular shutdowns. This is important to prevent miss-alignment and equipment failure. Gear Reducers maybe shipped WITHOUT lubrication. Refer to the manufacturer’s brochure for recommended lubrication. Failure to do so will void manufacturer’s warranty. *IT IS ESSENTIAL TO READ AND UNDERSTAND THE “INITIAL SETUP SECTION” PRIOR TO STARTUP.*


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EQUIPMENT SPECIFICATIONS

HIKON PORTABLE 4240-16' FEEDER C/W THE FOLLOWING SPECIFICATIONS - Basic chassis c/w - 49" tandem axle spring style suspension

- 11.00 x 22.5 radial tires - Budd style wheels

- Air brakes - Travel lights

- Mud flaps - 18” main rails

- Blocking points under hopper - Extended length on king pin end of chassis - 15 feet discharge conveyor overhang - Discharge conveyor c/w

- 42” wide belt - Four foot impact bed under receiving hopper - Luff trough sets spaced at a maximum of 42” - Rubber disced return rolls spaced at 10’ maximum - Full length skirting - 14” lagged head pulley c/w 2-15/16” shaft - 12” crown faced winged tail pulley c/w 2-7/16 shaft - Dodge TA #5 shaft mounted reducer c/w backstop - Belt drive c/w guard - 15 HP TEFC drive motor

- ¼ x 1/16 – 3 ply Conti Stacker Grade 375 PIW belting - Vulcanized belt splice - Manual adjustable discharge height - Rock roll back swing gate - Receiving hopper - Belt scraper on head pulley

- Belt Feeder c/w - 42” wide belt - 6” rubber impact rolls c/w 1-15/16” bearings spaced at 9” centers - Rubber disced return rolls spaced at 10’ maximum - 16” lagged head pulley c/w 3-7/16” shaft - 12” crown faced winged tail pulley c/w 2-15/16 shaft - Dodge right angle Quantis gear reducer - 15 HP TEFC drive motor - Chain drive between head pulley and gear reducer - ¼ x 1/16 – 3 ply Conti Stacker Grade 600 PIW belting

- Vulcanized belt splice


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- Belt Feeder continued - Belt scraper on head pulley - Removable cartridge style design - Non reversing feeder - Tail pulley cover plate and guarding - Hopper c/w - 8’ x 15’ top opening - Hydraulic grizzly with adjustable 16” openings - Standard Hikon grizzly bars - Electric over hydraulic control valve - 3/8” plate construction - Bottom 2 feet lined with QT400 – 1/4” plate - Sides of hopper are skirted with 3/16” ramp up plate - Less hinged door at tail end of feeder - Adjustable 1/2" x 6" QT400 steel flashing on inside of hopper

- General - All conveyor rolls are 5” diameter Luff brand - All bearings Dodge

- Mount for Vibco Model 2P-1700 on one side of the hopper - Complete chassis blasted and painted with Hikon grey Durathane paint

- Power cord package c/w - 100’ long cords for all motors - 30 Amp male cord ends - Cord hangers


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DELIVERY INSPECTION

PACKING SLIPS

These are provided to ensure a complete delivery. Items should be checked off as received.

MISSING ITEMS

If any items are missing after a thorough inspection, Hikon Industries Ltd. must be notified immediately.

DAMAGED ITEMS

Make note, on the freight bill, of any items damaged while in transit. Present the claim to the proper freight official and notify Hikon Industries Ltd.


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LIMITED WARRANTY

All equipment manufactured by Hikon Industries Ltd. is warranted to free of defects and workmanship when used under normal and proper use for a period of 12 months or 2000 hours of operation, whichever comes first, from delivery date. Components manufactured by other venders including electric motors, bearings, reducers, belts, pumps, etc. are subject to warranty coverage as covered by the individual suppliers. Normal wear and tear is not covered by this warranty. Warranty is in effect to the original owner only and is not transferable. All requests for warranty shall be made in writing to the Factory before the claim can be approved.

HIKON INDUSTRIES

PHONE: (306) 244-4533 FAX: (306) 244-5223


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SAFETY GENERAL PRECAUTIONS & WARNINGS A copy of this manual must be kept in the general vicinity of the equipment. It is important that “Owners, Operators, and Anyone” working with this equipment read and understand this manual. To ensure a safe workplace, all employees must be aware of and follow all local safety regulations and procedures. All employees must be aware of operation instructions, maintenance, service, troubleshooting, safety features and any automated functions. Common sense along with proper safety procedures will lead to a safe workplace. Safety is the responsibility of everyone and must be enforced by the owners and operators of the equipment. Always follow warning signs and lockout procedures. Be aware of your surrounding environment and those around you. Never remove safety features from equipment. Additional safety equipment may be required to meet local safety codes. The customer is responsible to review and determine if additional guarding is required. Anytime one is unsure about safety, consult the operation manual or a supervisor. Time is never a reason to compromise safety.

If a manual is lost or there are questions regarding the manual contact HIKON INDUSTRIES Ltd.

LOCKOUT Prior to any inspections, maintenance or service, equipment must be locked out. This means that every individual working on the equipment must have their own lockout tag. Lockout tags are to be provided by the employer. It is essential to prevent premature startup. The tags must identify the type of work being done and by who it is being done by. When the work is done, the individual must remove their own tag.

DECALS Decals are used to inform and warn. Prior to equipment operation, all personnel must read SAFETY DECALS. Decals must always be visible. At no time, may a decal be covered up or removed. If a decal becomes damaged or illegible it must be replaced. Contact Hikon Industries Ltd. for a replacement. Part numbers are located in the bottom right hand corner.


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DO’S & DON’TS -Always follow instructions and procedures

-Never assume anything

-Always keep a clean work environment

-Never operate or work on equipment without reading the manual

-Do not modify this manual

-Do not stand or climb on areas which aren’t designed for that

-Never operate equipment while intoxicated

-Always where protective clothing: ear plugs, hard hat, eye protection, gloves, work boots, dust protective devices and no loose clothing

-Always wear the proper harnesses when working in elevated areas

-Never bypass safety devices

-Never operate equipment without guarding in-place

-Never reach around guarding

-Only start equipment when it’s clear of personnel

-Never leave equipment operating while unattended

-Never overload equipment

-Do not operate equipment if safety devices are malfunctioning

-Only use OEM parts on equipment

-Never perform maintenance while equipment is operating

-Equipment must be locked out before servicing

-Make sure equipment is properly grounded

-Always watch for falling or ejected debris


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MAINTENANCE GENERAL Maintenance can only be performed when equipment is LOCKED OUT. Since the equipment usually has a large inertia force they do not stop abruptly. It is important to make sure all components are at a state of ZERO ENERGY. Any components that may move during the servicing must be blocked or restrained. Maintenance should only be performed by those who are trained to do so safely. A supervisor must know the whereabouts of all the maintenance personnel at all times. Preventive Maintenance is an important part of productive equipment. Replacing worn-out parts during scheduled shutdowns is much more beneficial than replacing broken parts during a production cycle. Some general rules to follow:

1) Check oil levels regularly

2) Lubricate components regularly (not while operating)

3) Monitor the motors power consumption

4) Keep machine and its components clean

5) Repair leaks quickly to prevent further damage

6) Monitor all vibrations

7) Replace broken or cracked components

8) Always consult the manufacturer prior to welding

9) Tighten all loose fittings and components

10) Regularly test safety equipment and shutoffs

11) Maintain proper belt tensions (both drives & conveyors)

12) Keep conveyor belts properly trained

If and when welding or cutting is required, the manufacturer must be consulted. Materials used on equipment are not all the same, so welding or cutting may be difficult/detrimental if the material properties are not known. Always protect hoses, belting, and any flammable materials when performing maintenance to prevent a fire or damage. A trained person with fire extinguishing equipment must be present when welding or cutting.


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LUBRICATION It is important to lubricate components and maintain proper oil levels. Refer to the manufacture’s brochures for lubrication and oil recommendations for bearings, reducers, motors, motorized head pulleys, crushers, screener, etc. Always check that the component is not permanently sealed before attempting to lubricate. Any adjusting bolts, pivot points, slides, etc. should be lubricated with standard oil with detergent.

PULLEY MAINTENANCE All pulleys should be checked for shaft tightness. It is important to inspect bushings for proper seating and cap screws for proper torque. This should be done at least once a week for the first month of operation, then during shutdowns thereafter. Pulley lagging must be checked for wear, cracks and bond. Faults in anyone of these will result in belt slippage. Inspect the ends of the pulleys for cracks or fatigue. If there is any sign of either, the pulley must be taken out of operation or fixed. Take-up pulleys and belt tension devices must be inspected. Excessive belt tension will cause premature failure of pulleys, bearings and shafts. Pulley alignment is critical. Misalignment can result in improper belt tracking which will cause premature pulley and idler wear. Pulleys must be kept clean and free of built up material. Only clean and service pulleys when equipment is not in operation and locked out. Bearings should be visually checked for excessive shaft movement and vibration during operation. Then check bearings for alignment, lubrication and tightness while equipment is locked out. Never operate the equipment without guarding in place.

BUSHING INSTALLATION & MAINTENANCE BUSHING INSTALLATION

Remove all paint, oil, grease and anti-rust inhibitors from the mating tapered surface of the bushing(s) and hub(s). Make sure that the shaft, bushing(s) and hub(s) are otherwise clean and free of burrs. Do not lubricate the bushing taper, the capscrews, or the product tapered bore and threaded holes. Lubricating these parts or surfaces could lead to breakage of the product. If the pulley is to be keyed to the shaft, make sure both shaft and bushing keyway(s) are clean, smooth and free of burrs. Check the key size with both shaft and bushing keyway(s). Key(s) should be placed into the shaft keyway(s) at this time. For conveyor pulleys requiring 2 bushings, shaft


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keyways must be in line with each other for proper bushing installation. To assure the proper transmission of torque, all bushings used in drive pulleys must be keyed to the shaft. Place the shaft into pulley, being careful not to damage the bore of the hubs. Then slip the bushings onto the shaft and into the hubs. Line up the drilled holes of the bushings with the threaded holes of the hubs. Place and hand tighten the capscrews into the threaded holes of the hubs. When satisfied with the position of the shaft, slightly tighten the capscrews so the bushings are snug in the hubs. With a torque wrench, alternately and evenly in one bushing only, tighten the capscrews to the recommended torque values. Do Not Tighten More Then Recommended Values. Make sure that the bushing flange face surfaces on both sides of the split are even.

BUSHING CAPSCREW RECOMMENDED TORQUE VALUES QD Size Torque (ft-lb) XT Size Torque (ft-lb) OTHERS Torque (ft-lb)

H 7.5 15 8 Q1 29 JA 5 20 16 R1 29

SDS 9 25 29 S1 70 SK 15 30 46 UO 140 SF 30 35 70 25-- 36 E 60 40 100 30-- 67 F 75 45 140 35-- 83 J 135 50 250 40-- 142 M 225 60 400 45-- 204 N 300 70 600 50-- 258 P 450 80 750 60-- 652 W 600 100 750 70-- 652 S 750 120 750 80-- 652 140 750

Never exceed recommended torque in attempt to pull bushing flange flush with hub face. When tightened there should be clearance. If bushing flange is pulled flush with hub face while tightening capscrews, check for undersized shaft. If the problem persists, call the manufacturer. Once satisfied, tighten the next bushing. BUSHING MAINTENANCE For the first month of operation inspect bushings, capscrews and check capscrew torque at least once a week and thereafter during periodic shutdowns. To remove the bushings all capscrews must be removed. Then insert the capscrews into the threaded holes of the bushing. Gradually tighten the capscrews alternately and evenly in one bushing only, until the bushing becomes loose. If the bushing doesn’t become loose immediately, tap on the hub with a hammer. Once satisfied, loosen the next bushing.


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HYDRAULIC MAINTENANCE All hydraulic components must be brought to a zero energy state prior to any repairs or maintenance. It is important to visually inspect hoses for wear, cracking and leakage on a regular basis. If hoses show any signs of damage, they must be replaced. For wear problems, it is best to locate the source and fix the problem to prevent continuous damage. Hose clamps must be kept tight. When repairing any hydraulic problem, it is very important to keep all components clean and free of contamination. After maintenance is completed, the hydraulic system must be checked leaks. Never repair any leaks while the system is pressurized. Always keep a safe distance away from any moving components and repair areas when initially pressurizing the hydraulic system. Hydraulic oil should be checked once a day. It is important that all cylinders must be retracted before checking oil. The oil temperatures and pressures should be monitored during normal operation periods. Breather caps and filters must be kept clean and in proper working condition.

TAKE-UPS Inspect take-up rod threads prior to adjusting to avoid non-repairable damage. Adjust take-ups on a regular basis to maintain proper belt tension and tracking. Lubrication of the take-ups is entirely up to the operator based on the surrounding working environment. Moisture, dust and corrosive materials all affect the take-ups differently. The take-ups are shipped dry from factory but supplied with grease fittings.

BELT TENSION & REPAIR Conveyor belts must be adjusted regularly. For new belting it is important to adjust tension in small increments as the belting stretches. Over tightening a new belt will permanently stretch it. Belting should be visual inspected on a regular basis. If the belting is damage it must be repaired or replaced. It is important to keep the belt trained. This helps to avoid damage and leakage.


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CONVEYOR BELT TROUBLE-SHOOTING

GOODYEAR CONVEYOR BELT TROUBLE-SHOOTING

A. Conveyor runs to one side at given point on structure 5 4 1 2 3 44 B. Particular section of belt runs to one side at all points on conveyor 6 7 - - - - C. Belt runs to one side for long distance or entire length of conveyor 39 8 5 1 2 3 D. Belt runs off at tail pulley 39 10 1 - - - E. Belt runs off at head pulley 33 10 1 3 - - F. Belt slip 34 33 31 10 4 - G. Belt slip on starting 34 31 33 - - - H. Excessive belt stretch 41 42 43 12 32 35 I. Grooving, gouging or stripping of top cover 13 14 15 16 - - J. Excessive top cover wear, uniformly around belt 19 20 10 8 36 - K. Severe pulley cover wear 4 9 10 17 11 27 L. Longitudinal grooving or cracking of bottom cover 4 10 9 33 - - M. Covers harden or crack 23 37 - - - - N. Cover swells in spots or streaks 21 - - - - - O. Belt breaks at or behind fasteners; fasteners pull out 24 22 12 23 - - P. Vulcanized splice separation 38 30 12 17 25 - Q. Excessive edge wear, broken edges 8 10 40 7 - - R. Transverse breaks at belt edge 18 25 26 - - - S. Short breaks in carcass parallel to belt edge, star breaks in carcass 16 17 - - - - T. Ply separation 29 30 23 - - - U. Carcass fatigue at idler junction 25 26 27 28 29 36 V. Cover blisters or sand blisters 45 21 - - - - W. Belt cupping - New belt 46 - - - - - X. Belt cupping - Old belt (was OK when new) 21 23 - - - -

1. Idlers or pulleys out-of-square with center line of belt re-adjust idlers in affected area. 2. Conveyor frame or structure crooked: straighten in affected area. 3. Idler stands not centered on belt re-adjust idlers in affected area. 4. Sticking idlers: free idlers and improve maintenance and lubrication. 5. Buildup of material on idlers: remove accumulation; improve maintenance, install scrapers or other

cleaning devices. 6. Belt not joined squarely: remove affected splice and resplice. 7. Bowed belt for new belt this condition should disappear during break-in; in rare instances belt must

be straightened or replaced; check storage and handling of belt rolls. 8. 0ff-centre loading or poor loading: adjust chute to place load on center of belt; discharge material in

direction of belt travel at or near belt speed. 9. Slippage on drive pulley: increase tension through screw take-up or add counterweight; lag drive

pulley; increase arc of contact. 10. Material spillage and buildup: improve loading and transfer conditions; install cleaning devices;

improve maintenance. 11. Bolt heads protruding above lagging: tighten bolts; replace lagging; use vulcanized-on lagging. 12. Tension too high: increase speed, same tonnage; reduce tonnage, same speed; reduce friction with

better maintenance and replacement of damaged idlers; decrease tension by increasing arc of contact or go to lagged pulley; reduce CWT to minimum amount.

13. Skirt boards improperly adjusted or of wrong material: adjust skirt board supports to minimum 1" between metal and belt with gap increasing in direction of belt travel; use skirt board rubber (not old belt).

14. Belt spanking down under load impact install cushion idlers. 15. Material hanging up in or under chute: improve loading to reduce spillage; install baffles; widen

chute. 16. Impact of material a belt: reduce impact by improving chute design; install impact idlers.


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17. Material trapped between belt and pulley: install plows or scrapers on return run ahead of tail pulley. 18. Belt edges folding upon structure: same corrections as for 1, 2, 3; install limit switches; provide

more clearance. 19. Dirty, stuck, or misaligned return rolls: remove accumulations; install cleaning devices; use self-

cleaning return rolls; improve maintenance and lubrication. 20. Cover quality too low; replace with belt of heavier cover gauge or higher quality rubber. 21. Spilled oil or grease, aver-lubrication of idlers: improve housekeeping; reduce quantity of grease

used; check grease seals. 22. Wrong type of fastener, fasteners too tight or too loose: use proper fasteners and splice technique; set

up schedule for regular fastener inspection. 23. Heat or chemical damage: use belt designed for specific condition. 24. Fastener plates too long for pulley size: replace with smaller fasteners; increase pulley size. 25. Imp roper transition between troughed belt and terminal pulleys: adjust transition in accordance with

Goodyear Handbook of belting. 26. Severe convex (hump) vertical curve: decrease idler spacing in curve; increase curve radius; consult

Goodyear Handbook of Belting for assistance. 27. Excessive forward tilt of trough rolls: reduce forward tilt of idlers to no more than 2 from vertical. 28. Excess gap between idler rolls: replace idlers; replace with heavier belt. 29. Insufficient transverse stiffness: replace with the proper belt. 30. Pulleys too small: use larger diameter pulleys. 31. Increase screw take-up tension to value determined from calculations. 32. Counterweight too heavy: lighten counterweight to value required by calculations. 33. Pulley lagging worn: replace pulley lagging. 34. Insufficient traction between belt and pulley: lag drive pulley; increase belt wrap; install belt

cleaning devices. 35. System underbelted: recalculate belt tensions and select proper belt. 36. Excessive sag between idlers causing load to work and shuffle on belt as it passes over idlers:

increase tension if unnecessarily low; reduce idler spacing. 37. Improper storage or handling: refer to Goodyear for proper storage and handling instructions. 38. Belt improperly spliced: resplice using proper method as recommended by Goodyear. 39. Belt running off-centre around the tail pulley and through the loading area: install training idlers on

the return run prior to tail pulley. 40. Belt hitting structure: install training idlers on carrying and return run. 41. Improper belt installation causing apparent excessive belt stretch: pull belt through counterweight

with a tension equal to at least empty running tension; run belt in with mechanical fasteners. 42. Improper initial positioning of counterweight in its carriage causing apparent excessive belt stretch:

check Goodyear Handbook of Belting for recommended initial position. 43. Insufficient counterweight travel: consult Goodyear Conveyor and Elevator Belt Selection Manual

for recommended minimum distances. 44. Structure not level: level structure in affected area. 45. Cover cuts or very small cover punctures allow fines to work under cover and cut cover away from

carcass; make spot repair with vulcanizer or self-curling repair material. 46. Excessive cover gauge ratio: use a belt with a lower gauge ratio and/or a thicker carcass.


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OPERATION INSTRUCTIONS PRE-OPERATION CHECKLIST

1) Read through the owner’s manual.

2) Check all greaseable components to make sure their greased.

3) Make sure reducers are filled to the proper oil level.

4) Check all other fluid levels.

5) Check for properly adjusted skirt board rubber.

6) Verify that all wiring is done and done by a qualified electrician.

7) Check the drive direction prior to installing drive belts. Backstops in reducer will be damaged if drive direction is wrong. Have motors rewired by an electrician if drive direction is wrong.

8) Check that all drives are adjusted.

9) Check for any loose or missing hardware.

10) Confirm that belt scrapers are properly installed and adjusted.

11) Adjust conveyor belts to the proper tension.

12) All guarding and safety devices must be in place and in working order.

13) Inspect all hoses and hose clamps.

14) Always make sure equipment is clear of all personnel prior to start up.

15) Make sure equipment is not locked out before operating.

16) Once operating equipment make sure gauges, indicators and controls are working.

17) Double check safety shutoffs.


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EQUIPMENT SETUP FROM TRANSPORT Before setting up equipment an adequate area must be selected. It is important to consider overhead and underground cables, maneuverability and functionality. All equipment must be cribbed or blocked. It is very important to have a level and solid footing. Equipment cannot become unstable while operating. It must be level and regularly checked. Once equipment is in position and blocked, any access ladders, etc. can be put into place. All adjustable components need to be locked into their working position. (Refer to Plant Specific Operating Instructions). While lifting components into position, always use the proper techniques. Everyone must be in clear view of the operator and in a safe zone. Electrical cables must be located away from traffic areas. Cables cannot become damaged; they must be repaired or replaced by a qualified electrician. Before startup one must go through the “Pre-Operation Checklist”. During operation it is important to pay attention to the equipment and surrounding environment. Always acknowledge unauthorized people approaching the equipment. Take note of the noise, vibrations, smells and output of equipment. If there are any changes in these, equipment should be observed closely to prevent further damage.

EQUIPMENT SETUP TO TRANSPORT As operations reach completion and equipment is being shut down for transport, several steps need to be taken. Prior to anything, equipment must be shut down and at a zero-energy state. The power cords must be disconnected and wrapped up. All components must be shifted and locked in their transport position. (Refer to Plant Specific Operating Instructions). Equipment should be cleaned off and the general area should be cleaned up. Tire pressure and wheel lug nut torque should be checked. A brake and light inspection must take place when a tractor is hooked on to any equipment. Warning signs and flags must be attached to equipment. Know and follow weight and dimensional restrictions. It is important to follow the recommended limits on towing speed.


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PLANT SPECIFIC OPERATING INSTRUCTIONS

TRANSPORT TO OPERATING POSITION Discharge Conveyor

1) Loosen and remove the ratchet strap from discharge conveyor.

2) Unwrap and connect power cord to the power van.

3) Support the discharge conveyor under the lifting channel.

4) Lift the conveyor.

5) Adjust height of conveyor and place the support bar in the nearest notch.

6) Lower the conveyor onto the bar.

7) Loosen the scraper rubber bolts under the feeder head pulley.

8) Adjust the rubber so it is tight to the feeder belt.

9) Tighten the scraper bolts.

10) Confirm drive direction prior to installing the drive belts to avoid damage to the backstop in the reducer.

11) When drive direction is correct install the drive belts and guard.

12) Train and track the belt. (Refer to "Belt Tension & Repair")

13) The conveyor is ready to use. Belt Feeder 1) Check and adjust the steel skirting in the hopper to avoid leakage.

Make sure there is slight clearance (approx. 1/8") to the belt to avoid cutting the belt.

2) Unwrap and connect power cord to the power van.

3) Train and track the belt. (Refer to "Belt Tension & Repair")


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General

1) Level and block the chassis.

2) Unwrap and connect the hydraulic power cord and control cord to the power van.

3) Cycle the grizzly up and down to confirm proper function.

IMPORTANT! INSPECT AND SERVICE PLANT FOR LOOSE OR MALFUNCTIONING HARDWARE PRIOR TO START-UP.

OPERATING TO TRANSPORT POSITION General

1) Make sure the grizzly is down.

2) The hopper must be empty.

3) Disconnect and wrap up all cords.

4) Remove built up and oversized material from around the plant.

5) Clean off any loose debris.

Discharge Conveyor

1) Support the discharge conveyor under the lifting channel.

2) Raise the conveyor just enough to remove the support bar.

3) Place the support bar in the notch.

4) Lower the conveyor onto the transport stops.

5) Attach the ratchet strap to hold down the conveyor.

OPERATION AND ADJUSTMENT Belt Feeder operation

1) The plant must be shut down and locked out prior to any work.

2) Maintain proper belt tension and track belt regularly.

3) Feeder belt speed must not be faster then the discharge conveyor belt speed.


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4) Removing the belt feeder: a) Shift the feeder drive all the way towards the hopper. b) Remove the feeder drive chain and the large sprocket. c) Remove the tail guarding. d) Remove all 4 conveyor mounting bolts and spacers. e) Raise the steel skirting to avoid cutting the belt. f) Sling the tail shaft of the belt feeder. g) Remove the conveyor. It is important to support the

conveyor as it is being removed to avoid damage to the equipment.

5) Installing the belt feeder:

a) Sling the belt feeder. b) Raise the conveyor with the proper equipment. c) Place the head end of the belt feeder on the support angles. d) Remove the head end support slings. e) With the belt feeder at the same angle as the support angles

slide it into position. f) Install the 4 spacers and mounting bolts. g) Install the tail guarding. h) Install the large sprocket and drive chain. i) Shift the reducer away from the hopper until proper chain

tension is achieved. j) Check and adjust the steel skirting. k) Replace any guarding that was removed.

Grizzly operation and adjustment

- The feeder is supplied with an electrical control valve (110V). - The customer supplies the switch to control the valve. - It is important to keep the grizzly clean and free flowing; a

buildup of material reduces capacity. - Do not close the grizzly when material is heaped in the hopper.

1) Adjusting grizzly bar spacing requires all the proper safety equipment and harnesses.

2) Remove the hardware from all the bars that need to be adjusted.

3) Shift, add or remove the bars.

4) Install all the hardware.


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General operation and adjustment 1) Regularly adjust skirt rubber to prevent leakage.

2) Train and adjust the conveyor belt(s) regularly.

3) Refer to manufacturer’s brochures and manuals for specific component maintenance.

4) Hang some weight from the head pulley scraper to maintain

scraping pressure. 5) Replace the scraper rubber once it has worn within 1/8” of the

scraper housing. Belt drive adjustment

Important! – The plant must be locked out when checking and adjusting the drive.

"D" "F" Discharge Conveyor 0.4" 6.4-6.7 lbs

FIGURE 1

Discharge conveyor belt drive

1) Remove the front drive guard panel.

2) Check belt tension.

3) To adjust belt tension, loosen torque arm jam nuts.

4) Adjust the turn buckle until proper belt tension is achieved.

5) Tighten the torque arm jam nuts.

6) Recheck the belt tension.

7) Install the front drive guard panel.


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PARTS PARTS LISTING QTY PART NUMBER DESCRIPTION 83'-11” 42" 1/4" x 1/16"-375-3ply Conti Stacker Discharge conveyor belt

(89’ including vulcanized splice allowance) endless length 34’-2” 42" 1/4" x 1/16"-600-3ply Conti Stacker Grade Belt feeder endless length (39’ including vulcanized splice allowance) 2 Vulcanized Belt splices 2 BX75 Discharge drive belts 10’ 140 Feeder drive chain 1 H9700-49” Tandem Suspension 2 D2216761616H94A (94" axles) Axles 4 CS-TRA2727 Springs Hutch 3 Leaf 3” 4 A2-3030GSB 30/30 Spring brake less clevis 4 BA-12-40202 1/2” Clevis 8 28408NE Wheels 8 11R22.5 Tires 8 573 Valve stems 1 KN28600 Regulator valve 2 241-B Drain cock 4 1201-03-02 Grizzly hinge bushings 9 BA-142-257-301 Impact bars 230L AW32 Hydraulic oil 3.75L Synduro SHB 220 Synthetic Multifunctional TXT5 Reducer oil Lubricant 8.3L Mobilgear 600 XP 220 mineral oil Quantis RHB reducer Feeder Conveyor Cord 1 ACP3034BC Male cord end 100’ 10/4 SOOW Power cord 1 2545 Strain relief 1 1” x 1.5” Reducer bushing Discharge Conveyor Cord 1 ACP3034BC Male cord end 100’ 10/4 SOOW Power cord 1 2545 Strain relief 1 1” x 1.5” Reducer bushing Hydraulic Pump Cord 1 ACP3034BC Male cord end 100’ 10/4 SOOW Power cord 1 2545 Strain relief 1 1” x 1.5” Reducer bushing


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Control Valve Cord 100’ 16/4 SOOW Power cord 1 2522 Strain relief

REPLACEMENT ROLLS

Troughset Part # Roll Part # Roll Quantity Roll Length Shaft Length CEMA Code Shaft Diameter

42" Belt42-253-HSE 5CS15 2 14.75" 16.125" C 25mm42-353-HSE 5CS15 8 14.75" 16.125" C 25mm


42" Belt42-254-HDE 5DD15 3 14.5" 16.125" C 25mm


3400 4-1/2" Brackets 945BPSR 3 Straight drop bracket 7-1/2" hole center

Shaft length is belt width plus 6.5" 42" Belt

42-053-HDR 42-053-HDRC 3 45.25" 48.5" C 25mm

RUBBER DISC RETURN ROLL 5" - LUFF TROUGHSET REPLACEMENT CHART

STEEL ROLL 5" - EQUAL ROLL - 20o AND 35o LUFF TROUGHSET REPLACEMENT CHART

IMPACT ROLL 5" - EQUAL ROLL - 20o AND 35o LUFF TROUGHSET REPLACEMENT CHART


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PARTS DRAWINGS


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MANUFACTURERS BROCHURES DODGE QUANTIS REDUCER


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DODGE REDUCER


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DODGE BACKSTOP


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ROLLER BEARINGS


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IMPACT BED

Impact Bed SIDE FOLD DOWN STYLE (SFD)

INSTALLATION AND SERVICE INSTRUCTIONS

ALL DRAWING, PICTURES AND SPECIFICATIONS IN THIS MANUAL MAY BE CHANGED WITHOUT NOTICE


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SAFETY

Important Safety Instructions

This symbol indicates important safety statements throughout this manual. READ THESE STATEMENTS CAREFULLY!

For the purpose of this manual and product labels, DANGER indicates death, severe personal injury or substantial property damage will result if proper precautions are not taken.

For the purpose of this manual and product labels, WARNING indicates death, severe personal injury or substantial property damage can result if proper precautions are not taken.

For the purpose of this manual and product labels, CAUTION indicates minor personal injury or property damage can result if proper precautions are not taken.

For the purpose of this manual and product labels, a qualified person is one who is familiar with the installation, construction and operation of the equipment and the hazards involved.


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SAFETY

SAFETY FIRST

Death, severe personal injury or substantial property damage can result if proper precautions are not taken when installing, operating, or maintaining this equipment. Due diligence must be practiced. Fully complying with all OH&S, owner, industry, provincial, and federal regulations during installation, operation and maintenance of this equipment.

Before installing, operating, inspecting, adjusting, replacing or servicing any part of this equipment, the conveyor must be shut down and locked out using industry acceptable Lock Out procedures. Acceptable Lock Out procedures are defined by OH&S, owner, industry, provincial, and federal regulations.

Proper personal safety equipment and clothing must be worn and only persons completely familiar with belt conveyor safety standards and the contents of this manual should be allowed to install, operate or maintain this equipment. It is very important that proper installation and mounting specifications are followed. Incorrect installation, operation or maintenance may result in belt wear, belt damage or personal injury. Read and fully understand the entire manual before installing, operating or maintaining this equipment. Do not exceed design loads or service conditions or modify this equipment in any way. Do not use this equipment in applications for which it was not intended. Make certain any guards removed for installation or servicing are promptly and properly replaced after completion of the work.

Im portant If you have any questions or do not understand the instructions contained in this manual, contact your loca l d i s tribu tor.


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SAFETY

TYPICAL MINIMAL LOCKOUT PROCEDURE

DEFINITIONS

Affected Employee An employee whose job requires him/her to operate or use a machine or equipment on which servicing or maintenance is being performed under lockout or tagout, or whose job requires him/her to work in an area in which such servicing or maintenance is being performed.

Authorized Employee A person who locks or implements a tagout system procedure on machines or equipment to perform the servicing or maintenance on that machine or equipment. An authorized employee and an affected employee may be the same person when the affected employee’s duties also include performing maintenance or service on a machine or equipment, which must be locked, or a tagout system implemented.

Capable of Being Locked Out An energy isolating device will be considered to be capable of being locked out either if it is designed with a hasp or other attachment or integral part to which, or through which, a lock can be affixed, or if it has a locking mechanism built into it. Other energy isolating devices will also be considered to be capable of being locked out, if lockout can be achieved without the need to dismantle, rebuild, or replace the energy-isolating device or permanently alter its energy capability.

Energized Connected to an energy source or containing residual or stored energy.

Energy Isolating Device A mechanical device that physically prevents the transmission or release of energy, including but not limited to the following: A manually operated electrical circuit breaker, a disconnect switch; a manually operated switch by which the conductors of a circuit can be disconnected from all ungrounded supply conductors and, in addition, no pole can be operated independently; a slide plate; a slip blind; a lime valve; a block; and any similar device used to block or isolate energy. The term does not include a push button, selector switch, and other control circuit type devices.

Energy Source Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other energy.


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SAFETY

Lockout The placement of a lockout device on an energy-isolating device, in accordance with an established procedure, ensuring that the energy isolating device and the equipment being controlled cannot be operated until the lockout device is removed.

Lockout Device A device that utilizes a positive means such as a lock, either key or combination type, to hold an energy isolating device in the safe position and prevent the energizing of a machine or equipment.

Normal Production Operations The utilization of a machine or equipment to perform its intended production function.

Servicing and/or Maintenance Workplace activities such as constructing, installing, setting up, adjusting, inspecting, modifying, and maintaining and/or servicing machines or equipment. These activities include lubrication, cleaning or unjamming of machines or equipment and making adjustments or tool changes, where the employee may be exposed to the unexpected energization or startup of the equipment or release of hazardous energy.

Setting Up Any work performed to prepare a machine or equipment to perform its normal production operation.

Tagout The placement of a tagout device on an energy-isolating device, in accordance with an established procedure, to indicate that the energy isolating device and the equipment being controlled may not be operated until the tagout device is removed.

Tagout Device A prominent warning device, such as a tag and a means of attachment, which can be securely fastened to an energy isolating device in accordance with an established procedure, to indicate that the energy isolating device and equipment being controlled may not be operated until the tagout device is removed.

PROCEDURE

Sequence of Lockout 1. Notify all affected employees that servicing or maintenance is required on a

machine or equipment and that the machine or equipment must be shut down and locked out to perform the servicing or maintenance. The authorized employee shall refer to the company procedure to identify the type and magnitude of the energy that the machine or equipment utilizes, shall understand the hazards of the energy, and shall know the methods to control the energy. If the machine or equipment is operating, shut it down by the normal stopping procedure (depress stop button, open switch, close valve, etc.). De-activate the energy isolating device(s) so that the machine or equipment is isolated from the energy source(s).

2.

3.

4.


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SAFETY

5. 6.

Lock out the energy isolating device(s) with assigned individual lock(s). Stored or residual energy (such as that in capacitors, springs, elevated machine members, rotating flywheels, hydraulic systems, and air, gas, steam, or water pressure etc.) must be dissipated or restrained by methods such as grounding, repositioning, blocking, bleeding down, etc. Ensure that the equipment is disconnected from the energy source(s) by first checking that no personnel are exposed, then verify the isolation of the equipment by operating the push button or other normal operating control(s) or by testing to make certain the equipment will not operate.

7.

Return operating control(s) to “neutral” or “off” position after verifying the isolation of the equipment.

The machine or equipment is now locked out. 8.

Restoring Equipment to Service When the servicing or maintenance is completed and the machine or equipment is ready to return to normal operating condition, the following steps shall be taken: 1. Check the machine or equipment and the immediate area around the machine or

equipment to ensure that nonessential items have been removed and that the machine or equipment components are operationally intact. Check the work area to ensure that all employees have been safely positioned or removed from the area. Verify that the controls are in neutral. Remove the lockout devices and reenergize the machine or equipment. Note: The removal of some forms of blocking may require re-energization

of the machine before safe removal. Notify affected employees that the servicing or maintenance is completed and the machine or equipment is ready for use.

2.

3. 4.

5.

Group Lockout or Tagout When servicing and/or maintenance is performed by a group they shall utilize a procedure which affords the employees a level of protection equivalent to that provided by the implementation of a personal lockout or tagout device. Specific procedures shall be utilized during shift or personnel changes to ensure the continuity of lockout or tagout protection, including provision for the orderly transfer of lockout or tagout device protection between offgoing and oncoming employees, to minimize exposure to hazards from the unexpected energization or start-up of the machine or equipment, or the release of stored energy.


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SAFETY

Im portant

A good safety program makes provisions for hazard identification, open lines of communications, allocation of responsibilities, record keeping, training and, regular inspection and program audits both internal and externally conducted. Communication is the key to improving the effectiveness of safety programs. Post all regulations, safety reminders, results of safety audits, newly found hazards, etc. All personnel should be encouraged to ask questions and to bring safety related matters to the attention of everyone. All personnel need to be “Proactive” not “Reactive” when it comes to safety. Anticipate possible accidents and continually review the workplace for possible hazards. All employees have accountability to themselves and their colleagues to achieve safety excellence. Safety needs to be an integral part of every employee's job and a working climate needs to be developed where safety is highly valued by each and every employee. Educating and training employees is mandatory to achieve safety excellence. In addition to the applicable company, industry, provincial and federal regulations, the latest edition of the following codes and standards are recommended for your safety training programs and information/reference manuals:

1. ANSI/ASME B20.1 Safety Standards for Conveyors and Related Equipment American National Standards Institute / The American Society of Mechanical Engineers ANSI/ASME B15.1 Safety Standard for Mechanical Power Transmission Apparatus ANSI Z244.1 Personnel Protection - Lockout/Tagout of Energy Sources - Minimum Safety Requirements MSHA Guide to Equipment Guarding at Metal and Non-metal Mines U.S. Department of Labour, Mine and Health Administration CEMA Publication No. 201 Safety Label Brochure Conveyor Equipment Manufacturers Association CSA Z432 Safeguarding of Machinery Canadian Standards Association ISO 1819 Continuous mechanical Handling Equipment - Safety Code - General Rules International Standards Organization ISO 5045 Continuous Mechanical Handling Equipment - Safety Code for Belt Conveyors - Examples for Guarding of the Nip Points ISO 7149 Continuous Handling Equipment - Safety Code - Special Rules

2.

3.

4.

5.

6.

7.

8.

9.


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INSTALLATION AND SERVICE INSTRUCTIONS

Our Impact System is a proven, reliable system for handling severe impact loads experienced at the loading point of bulk material handling belt conveyors.

The system consists of four-foot long impact bars with four impact frames and f ive-foot long impact bars with f ive impact frames. Heavy-duty applicat ions may require addit ional frames. Special lengths can be made by placing addit ional bars and frames in-line with each other. Bars may also be saw-cut to special lengths. Standard systems are available for 20 O and 35 O troughing angles.

Whatever the length and troughing angle ordered, these parts are shipped unassembled: impact stands, impact bars, and fasteners.

Complete assembly, as shown on the drawing is accomplished at the installat ion site.

Reliable operation and long service life depend on the care taken during installat ion.

The maximum operating temperature for the Impact System is 185 O F (85O C).

Safe practices for operating belt conveyors are given in American National Standards publication, " Safety Standards for Conveyors and Related Equipment” ANSI B20.1, Section 5 and 6.01.

Proper personal safety equipment and clothing must be worn and only persons completely familiar with these standards should be allowed to operate or maintain this equipment. Failure to observe these safety precautions and other specific procedures emphasized throughout these instructions may result in personal injury or damage to equipment.


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IMPACT SYSTEM INSTALLATION

Before installing the system on an existing belt conveyor, be certain the conveyor is stopped and locked out to avoid injury and property damage.

1. Prepare conveyor stringers for installation of the base frame assemblies. Refer to the drawings for spacing of frames. Note the difference for four and five foot standards. We recommend a steel roll troughing idler 3" - 12" from each end of the impact bars making sure they are outside any impact area.

2. If a standard four or five foot system is going to be extended in length, the last frame must be shifted by three inches to enable the ends of both adjoining bars to rest on the same support frame. The base frame and the impact bar supports have holes on both flanges to accept impact bar fasteners from both adjoining bars.

3. Prepare customer supplied shims for installation between conveyor stringers and base frames. Shim thickness must be calculated to provide the specified clearance between conveyor belt and top of impact bars. (Shimming of idler frames may be necessary to achieve recommended clearance.)

Note: The recommended clearance varies with the length of the impact bed system. The longer the length, the greater the clearance.

Recommended Clearance

4. Remove mud, stones or any other debris from conveyor stringers and deck plate. Remove all burrs, dents and bumps caused by excessive weld splatter so that the impact system frames can be securely positioned level with the plane of the conveyor and perpendicular to the line of conveyor belt travel.

5. The Impact System may be completely assembled and placed on the stringers as a unit, if space permits (See Illustration 1). If not, proceed to assemble as follows.

IMPACT BED LENGTH CLEARANCE

4 ft. 3/4"

5 ft. 3/4"

8 ft. 1-1/4"

10 ft. 1-1/2"

Specials (over 10 ft.) Normally 1 percent of Idler Spacing


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6. Place shims and frames on the conveyor stringers as shown in Illustration 2.

ILLUSTRATION 1 ILLUSTRATION 2

7. Bolt-base frame securely to the stringers using customer supplied bolts.

8. Assemble center impact bars to the base frame channels. Use ONLY one T-threaded bolt for each base frame, i.e.; four bolts per impact bar for four foot length; f ive bolts per impact for a f ive foot length. Also be sure to use the bevel washers provided.

Note: Slide T-headed bolt into impact bars, as shown on Illustration 3 and bolt to base as shown on Illustration 4.



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A complete fastener assembly consists of T-bolt, f lat washer or bevel washer and lock nut. See I l lustrat ion 5a and 5b. Use the f lat washer when connecting the bars to the side supports. Use the bevel washer when fastening the bars directly to the channel base frame.

Tighten T-bolt nuts to 35-40 lb.-ft. All other fasteners to be tightened to 45-50 lb.-ft.

9. Assemble impact bar supports (t-bars) to the base frame, using fasteners provided.

Note: The lower end of each t-bar has two holes. For 35O troughing, use the hole nearest the end. For 20O troughing, use other hole. See Illustration 6.

ILLUSTRATION 5b ILLUSTRATION 5a

ILLUSTRATION 6


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10. Install the impact bars to the T-bars. Tighten the fasteners.

11. Raise the troughing sections and install the support arms with fasteners provided (See I l lustrat ion i l lustrat ion 8).

7), to make a complete assembly (See


12. Tighten all frame fasteners so that the steel members at each bolt are pulled together t ightly to make a ridged assembly.


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MAINTENANCE

Before maintenance is performed on the system be certain the conveyor is stopped and locked out to avoid injury and property damage.

This impact system is self-contained and basically maintenance free.

By removing the support arm, the troughing sections can be lowered for easy inspection and replacement of bars. Impact bars need to be replaced when the top UHMW polyethylene is worn through.

One size impact bar f its all frames at all loading points, unless special lengths are involved.

The impact bars and fastener assemblies are the only components that need to be inventoried. See drawings for number of bars required per belt width.

Do not allow constant contact between belt and horizontal impact bars: see page 11 for proper clearance. preventing spillage.

The belt edges will contact the impact bars,

Periodically check to see that all fasteners are tight.


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Only one (1) T-Bolt is required per Impact Bar per Frame. The Frames are manufactured with one (1) extra hole per Frame to simplify installation by avoiding the need for Right and Left hand assemblies. Only four (4) T-Bolts are required to fasten a 48" bar to the Frames and five (5) for the 60" Bar. Use ½" standard bevel washers [16-2/3% slope, ≅9.5°] when bolting directly to channel flanges. Torque lock nuts for T-bolts to 35-40 lb-ft. For further instructions and safety precautions please refer to the “Installation Manual” prior to installation.

Important Notice


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TB WOODS BELT DRIVE TENSION


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TB WOODS BUSHING


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WEG MOTOR


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owner’s manual · 2020. 12. 23. · owner’s manual “operation, maintenance & parts”...

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